Drug making is a hard, closely watched step-by-step process. It turns good science ideas into meds that are safe and work well for people. This long path usually takes 10-15 years and uses up billions of dollars. It has many parts: research, tests, and getting the okay from those in charge.
The Foundation of Drug Development
The drug development process starts way before any tests on people. Scientists first find and know about biological targets — key parts like molecules, genes, or cell processes that play a part in sickness. After a lot of study, they figure out how changing these targets could help treat or stop sickness. This key knowledge sets the path for the whole development process.
Today’s drug development depends a lot on new tech like artificial intelligence, computer models, and fast screening systems that can check thousands of bits very quickly. These tools let researchers find good drug options faster than the old ways.
Discovery and Early Research Phase
During the discovery phase
Researchers look at many different bits and pieces that might link up with their set target. They check out big groups of molecules, both man-made and from nature, to see which ones work as they want. They might test loads of compounds before they find a few that could be useful for treatment.
Once promising compounds are spotted
Researchers do deep study in labs to learn more about them. They see how the compound acts under various situations, if it stays the same, and how it could be made in big amounts. This first study shows if a compound might really turn into a good drug.
Preclinical Testing: Safety First
Before testing on people can start, building a drug needs a lot of early study.
These studies use lab tests and animal models to look at safety and how the drug works on a bio level. Researchers study how the body deals with the drug, looking at how it’s taken up, sent around, broken down, and thrown out.
Toxicology studies are key in early testing.
Scientists need to find safe dose ranges and see if there are any bad effects. They look at if the stuff might hurt organs, mess up reproduction, or cause cancer. Only stuff that shows it is safe in these tough tests can move to tests on people.
Clinical Trials: The Human Testing Phases
Clinical trials are the big and long part of making a new drug. These well-managed tests happen in clear steps, each meant to check the drug’s safety and how well it works.
Phase I Trials:
This first stage uses a small bunch of healthy folks or ill people, usually from 20 to 100. Main goal here is to check for safety and find the right dose. Scientists watch the people close to see how their bodies deal with the drug and spot any bad effects.
Phase II Trials:
Now, the testing grows to several hundred people who have the sickness the drug aims to fix. At this stage, they check if the drug seems to work and keep an eye on safety. They might try different doses or ways to give the drug to get the best treatment steps.
Phase III trials are big studies with hundreds to thousands of people in many places. These key trials match the new drug with old treatments or fake pills, giving clear proof it works. The info from Phase III trials is the main thing used when deciding if a drug should be okayed.
Regulatory Review and Approval
In making drugs, firms join hands with groups that check on drugs, like the FDA in the US or the EMA in Europe. These groups look at info at many points to make sure that the work goes on safe and by the rules.
When tests show a drug is safe and works well, firms ask for a green light to sell it.
These asks can have loads of pages that cover all parts of making, making sure, and testing the drug.
People who know the rules study this info a lot, and it might take months or years to finish their check.
Post-Market Surveillance
Continuous Monitoring After ApprovalDrug making does not end when it gets the green light from the ones in charge. After a drug is out for the people to buy, it keeps being watched. This goes on through Phase IV trials and checks after it is on sale. These steps watch how the drug does when it is used in daily life. They look for any bad side effects that did not show up before.
Role of Healthcare Providers and PatientsBoth those who give care and those who get it have a role. They tell when bad things happen with a drug. This helps those in charge and the makers know how safe the drug is when used for a long time. This never-ending watch can change the drug’s label, add new cautions, or even, though rarely, pull it from sale if it’s found to be very unsafe.
Manufacturing and Quality Control
Parallel to clinical development, companies must set up trusted manufacturing processes.
Drug making means making ways to always make good meds in big amounts.
This has making tests to check med quality, setting up supply lines for raw stuff, and making or hiring places to make the stuff.
Quality control steps make sure every batch of meds is up to high purity, strength, and sameness standards.
Rules people check the making places and look at quality info to make sure companies keep up these rules all through a drug’s time on the market.
The Economics of Drug Development
The cost of making drugs is a big deal for health care and getting medicine to people. The high price tags are due to successful drugs and many that do not make it through tests. It is said that only one in thousands of hopeful drugs gets the okay from authorities. These money facts steer choices all through the drug making steps. Firms have to weigh the hope held by science against money-making chances. They think about things like how big the market is, other firms making similar drugs, and how much they might charge. Knowing how all this works sheds light on why some sicknesses get more study than others.
Future Directions in Drug Development
The way we make drugs changes fast with new tech and big science wins. Custom medicine plans use gene info to make tight-fit therapies for set groups of people. Gene and cell therapies are whole new ways to treat that need new ways to be made and checked.
Computers that learn on their own are now big help in making drugs by guessing how mixes act, finding new drug spots, and making better test plans. These techs help us make drugs faster and cheaper, which may bring new help to sick folks sooner.
Conclusion
Drug making is one of the hardest and most rules-heavy jobs in today’s science and trade world. From the first find to watching over it after it hits the market, every step has key roles in making sure that new drugs are safe and work well. While this work takes a long time and costs a lot, it runs needed tests to keep public health safe and bring new cures to people who need them. As tech gets better and we learn more about diseases, the way we make drugs will keep getting better, too. This could mean we get new meds out faster but still keep them very safe for folks who use them.
HEPA filter, High-Efficiency Particulate Air/ High-Efficiency Particulate Arrestance Filter / High-Efficiency Particulate Absorbing Filter is known as HEPA filter denote higher degree of efficiency. The efficiency level denote the grade of the HEPA filters. There are several grades of HEPA filters available as per their area of application.
A standard HEPA filter must remove the particles from the air at least 99.5%[EU standard] or 99.97%[ASME,US.DOE] having particle diameter equal to 0.3 μm and subsequently increase efficiency with particle diameter greater than or equal to0.3 μm.
All type of standards HEPA filter generally retain particle and microorganism like dust, pollen, dirt, moisture, virus (0.02-0.3 μm), bacteria (0.2-2.0 μm), Bacillus subtilis, submicron liquid aerosol (0.02-0.5 μm), Penicillium citrinum, Aspergillus niger, Clostridia, Staphylococcus epidermidis, Bacilli, Bacteroidia, photocatalytic oxidation (PCO) etc.
HEPA filters use in wide area since its commercialization at 1950 where need to control contamination-
Aerospace industry
Cosmetic industry
Materials dispensing area
Electronics
Food Industry
Hard disk drives mfg. industry
Hospitals
Medical devices
Microbiological Lab
Nuclear Plant
Pharmaceuticals
Sterile products mfg. facility
Semiconductor industry
Vaccine and blood products mfg. area
Vehicle industry
Type of HEPA filters
Generally HEPA filters can be classified as [A], [B], [C], [D], [E] and [F]. Types testes are demonstrates on the following table.
How it works?
All type of HEPA filters are generally composed of mat where fibers are randomly arrange, these fibers are actually set of poly propylene or fiberglass varies diameter between 0.5 and 2.0 micrometers. Frequently use tangled bundles of fine fibers to prepare these filters. Air passes through the convoluted pathway crated by the tangled bundles of fine fibers.
Actually this fibers act like sieve which retain the big particles which subject to try pass through it. Most time the smaller particles can’t hold its motion when they are passed with air, in result the small particle crush with the fibers. As per Brownian motion, the small particle possess the little materiality to move randomly with air as these particles are suffered to bombard action.
As the small particles crush with the fibers, here the key factors are mainly filter thickness, fiber diameter and velocity of the air. The air space between the HEPA filter subject to greater than or equal to 0.3 μm provide high level of efficiency. In sieves or membrane filters, particles which are less than the pore or openings can pass through but in HEPA filters the particles are attached to the fibers. There are several mechanisms has been identified which play the major role trap the particle to the pore.
Diffusion
All the particles under 0.3 μm retained by the HEPA filter in diffusion method. This the main theme of the Brownian motion where smaller particle below or equal to 0.1 μm in diameter are hindered and trapped in the filter. This mechanism is not prominent is low velocity of air.
Interception
Particles which are subject to flow in a line come with same radius/diameter of a fiber and adhere to it, this is very prominent to mid-size particle and which are retain by this process.
Impaction
Particles with higher diameter subject to unable to pass the fibers and directly retain on them, the effect increase subsequently with the air velocity.
Particle having size at or below 0.1 μm diameter, diffusion method is predominant and particle above0.4 μm predominant to impaction and interception. The MPPS [Most Penetrating Particle Size] is 0.21 μm, here the impaction and interception are remarkably inadequate. And this this point consider the weakest point of HEPA filter. The classification of the HEPA filters remarkably depend on the particle retention capacity at or below or equal to 0.3 μm particle size.
What is Gas filtration?
All types of HEPA filters are designed to retain particles but HEPA filters are unable to retain odor and gases molecules. HEPA filters can’t filter the odor or gases molecules. Alternative have been developed by British Armed Forces[BAF]. To filter the chemical vapors, organic compounds, volatile compounds, pet, cigarette, or flatulence odors, activated carbon filter or other filters are used.
HEGA [High Efficiency Gas Adsorption] filters plays the major role here, composed of Carbon cloth filters which is more efficient than granular activated carbon form. This filters [HEGA] designed by BAF to face chemical warfare.
Effective Usage of HEPA filter with Pre-filter
In a common air handing unit, a pre-filter[Carbon activated] use with the HEPA bag filter to extend the usage life/shelf life of more expensive HEPA filter. At the first stage of the filtering the pre-filter, removes the almost all type of dust, hair, particle from the air. Particles which can’t remove by pre-filters or escape from it then the fine particles remove by the HEPA filters in AHUs[air handling units].
Specifications of HEPA Filter
HEPA filters are defined by the US, DOE[United States Department of Energy] in almost all American industry which removes at least 99.97% of particulate at 0.3 μm in diameter. At the standard volumetric air flow, the minimal resistance of the air flow or pressure drop is around 0.044 psi[300 pascals].
In EU, filters are classified based on MPPS [Most Penetrating Particle Size] as HEPA, EPA, and ULPA where the average efficiency defined as “Overall” and the specific point efficiency defined as “Local”.
Marketing View Regarding HEPA Filter
Now a days some of the company highlighted the term “True HEPA” supposed to give assurance to the end user/customer to confirm that their filter is the original HEPA filter. This term “True HEPA” has no significant scientific value or no legal meaning. Some of the company marketed as designed as”99% HEPA”,”HEPA-style””HEPA-like,” “HEPA-type,” etc. which didn’t comply the HEPA standard[99.97% efficiency] and this type of material may not have the original test certificate of may not undergo any type test like filter integrity test.
Safetyconsideration of HEPA Filter
Mid-size particles ranges between 0.15 µm and 0.2 µm is considered hardest to filter through HEPA. The mechanism of working of HEPA filter is totally different from Ionic filters and Ozone filters which work through negative ions and ozone gas respectively. So HEPA plays a great role in pulmonary side-effects like asthma and allergies which are much lower with HEPA filters.
Where the HEPA filters subject to use in commercial grade, it is better practice to change the HEPA filter in every six month to hold its efficiency at desired level of work but if it use in residential purpose then it may be change in every two to three years. In the period of time, the efficiency of HEPA filters decrease day by day and failing to change the same in due to create hazard to the machine or system and particulate contamination spread day by day.
Applications of HEPA filters
Biomedical
HEPA filters generally remove the air borne particle, bacteria, virus and various type of organism resulting infections. High energy ultraviolet light units or panels with anti-microbial coating integrated HEPA filters are specially use to serve medical purpose to kill the live bacteria and virus which trapped by the filter media. Airborne disease transmission successfully protect by the special design HEPA filter which efficiency declared as 99.995%.
Heating, ventilation, and air conditioning[HVAC]
HVAC [Heating, ventilation, and air] technology uses HEPA filters to remove airborne particulate, dust, microorganism etc. in indoors and vehicle, greatly use in sensitive pharmaceutical product manufacturing where subject to clean room class. To ensure better environment and better health, HVAC play a major role various organization who are concern this activities.
COVID-19
HEPA filters plays a great role to get entrapped SARS‑CoV‑2 Airborne droplets which size approximately 0.125 µm even if they are present on the floor. Various type of HEPA incorporated mask are available at the current market which is the best solution to prevent the pandemic situation for personal use.
Motor vehicles
HEPA filters is using in the latest car, “Tesla Mode X” using HEPA filters since 2016 and now their update “Model S” also using the additional HEPA filter.
Vacuum cleaners
HEPA filters are also use in many well designed vacuum cleaners as a part of their filtration systems. This option of the vacuum cleaners plays beneficial role for the patients having asthma and allergy problem due to HEPA filters traps fine particles reduce to size 0.1 µm which is mainly responsible to induce asthma and allergy. Before using the Vacuum cleaner integrated with HEPA filters, check the filter efficiency [at least 99.97%] unless authorized. HEPA like, True HEPA, HEPA are not the actual term to declared standard HEPA efficiency.
A powerful motor is essential to provide adequate cleaning power due to the high density of the HEPA filters. A vacuum cleaners containing washable HEPA filters subject to more expensive. A standard high quality HEPA filter generally trapped the particles having 0.3 µm in diameter where a natural human hair is 50 to 150 microns in diameter. So a HEPA filter traps the particle which are reduce to several hundred times smaller than the standard width of Human hair.
Sometimes, is remarkably noticeable that some of the manufactured declared HEPA 4/HEPA 3/HEPA 2 etc. without proper explanation behind them. This is actually declares their MERV [Minimum Efficiency Reporting Value] rating. This the ability of the air cleaner filter to remove the particle, dust, and microorganism etc. which passes with air through the filter. The MERV scale distributed between 1 and 16 which declare the efficiency of the filters remove particle between 10 to 0.3 µm in size.
Vehicles
Airlines
All types of modern airlines uses HEPA filters to reduce contamination in the air. As most of the air in air plane cabin is recirculated, so this is crucial to filter the air using high grade of HEPA filters to avoid cross contamination.
Maximum quantities of standard pressurized aircraft brought air from the outside and circulate it the cabin exhausted it through the outflow valves in the rear side of the respective aircraft. Almost 60% of air comes from outside of the plane and 40% cabin air passes through the HEPA filters in well-designed aircraft.
What are drawback of HEPA filters?
Every filtration technology has the shortcomings that no filter can pass the 100% contamination free air. The efficiency is almost 99.9997% not 100% same for HEPA filters. Besides this the HEPA filter has the following two types of drawback which can dissatisfy to you to buy a HEPA filter/HEPA filter integrated equipment’s-
Insignificant Pollutants Can Escape Filter:
HEPA filters are effectively act on the particle size at equal to or above 0.3 µm, there various type of microorganism which particles are reduce <0.1µm can easily pass the HEPA filters. So using HEPA filters you can trap/remove all type of organism, this myth is actually invalid. The smaller particulate cause the serious health hazard for the patient/personnel who are previously suffering from asthma or allergic problem. Alternative technology should be used to face this tiny size particles.
Various type of Mold & Bacteria Growth on Filter:
When bacteria and mold gather on the air system on the HEPA filter, this accumulate organism have the potential chance to grow in geometric order. As the number of the microorganism tend to grow outside the filter then the health hazard outside the controlled environment growth day by day. To solve this issue, a UV light integrated HEPA filter to be use to kill the mold and bacteria at your indoor environment.
So what is the best alternative of HEPA filters?
The best alternative of HEPA filters are ULPA [Ultra-low Penetration Air] filters. HEPA filters remove particles size equal to or above 0.3 µm having efficiency of 99.97% where ULPA filters remove particles size equal to or above 0.12 µm having efficiency of 99.999%.
Can HEPA filters be Wash or Reuse?
All type of HEPA filters can’t wash. Some of the HEPA filter can be wash and some are not. If your HEPA filter labelled with“Washable” then you can wash the HEPA filter but a non-washable HEPA filter may be wash by appropriate way.
To rinse a HEPA filter decrease its efficiency and proper study didn’t found that how much efficiency loss upon rinsing the HEPA filters. Moreover, this has been proved that upon rinsing the HEPA filter, its efficiency loss due to losing/damaging of fiber occur in this time.
During cleaning of HEPA filter, if individual face lack of awareness, fall in serious health hazard upon accidentally taking some of pollutants from HEPA filter. After cleaning, drying activity must complete for a long time. Check the same before use as the wet filter is the great source of mold.
HEPA filters can be reuse if you can clean it properly. Use a vacuum cleaner to clean the filter rather than rinse it. Even non washable filter can be clean this way, proper measures to be taken before cleaning the HEPA filter. Avoid direct touching it. If you rinse your filter, the dry the filter properly by placing it outdoor. Before placing, shake the it to remove the water properly. Set it at outdoor in such way that it get air from all direction and faster the drying process.
After washing the filter may withheld its efficiency maximum 99.7% and you can was your filter every six months or once in a year but it is the best practice to replace the same. Some of the filter labelled with “Permanent” then you can’t wash it, just replace it.
Mix up can be defined as taking something which is not subject to take; taking one thing to another. Taking wrong item unintentionally which can be easily identified such as taking Aceclofenac tablet in place of Metronidazole tablet having different size and shape. Mix up is a mix of diverse item but essentially contaminated. For example one blister strip of batch [A] tablet found with another batch [B] tablet.
Mix up is
Assume wrong item to right thing
Failure to take right action on due time
Mixture of various item/elements
Selection of wrong item
Selection similar product/material/item
Unintentionally taking one thing to another
Wrong selection of desired material
Wrong action taken due to lack of attention
Probable cause of Mix up
Breakdown of processing equipment.
Collation/procure similar packaging/printed material from same vendor.
Conducting packaging operation in other than main packaging belt.
Discontinuous packaging/partial packaging of single batch.
Engaging untrained/partial trained personnel.
Engaging single operator to multiple packaging line.
Failure to follow written procedure for line clearance.
Inappropriate labelling.
Improper segregation of products/item during manufacturing operation.
Improper labelling during dispensing.
Inadequate controls.
Manual operation other than automated system
Multiple product packaging operation in insufficient packaging area.
No barcode/QR code/Identification code
Process validation not properly conducted
Previous batch item such as label, carton, accessories etc. not removed properly
Rejection material handling
Reprocess
Rework
Return of IPC checks item to the wrong/ similar packaging belt.
Repackaging and packaging of similar product/item.
Similar Size, shape, color of multiple products.
Similar design of primary packaging/secondary material.
Similar product line clearance in same time.
Same instruments/apparatus use for multiple item/products/material.
System failure
Wrong labelling
Contamination
Contamination can be defined as the presence of undesirable element, impurity or constituent which infects, corrupts, spoils, makes substandard or makes unhealthy a factory, normal environment, physical body, material, process steps, bulk, liquid, granules, solid etc.
As per US FDA, contamination can be defined as-
Type of Contamination
Non-Viable
Liquid or solid particulate contamination range from 001 and 1000 microns such as smoke, dust, fogs, fumes, and mists.
Viable
Particulate contamination that supports, or consists of one or more live microorganisms such as Viruses, Bacteria, and spores.
Sources of Contamination
Atmosphere
Clothing
Equipment
Fluid
HVAC System
Manufacturing Debris
Premises
People
Processing Operations
Surface
Utilities and Services
Various source of contamination has been illustrated on the respective table-
Contamination of products can be caused by:
Contaminated dress/attire
Contaminated equipment/apparatus/instruments
Contaminated or damaged HVAC system
Contaminated Premises/sites/areas
Individuals, e.g., carrying harmful bacteria
Processing Operations negligibly
Utilities/Services/facilities
Cross Contamination
Cross Contamination can be defined as unintentional transfer of chemical contaminants, microorganism from one person, food, and object to another person, food.
Risk of cross contamination
The involving risk of cross contamination depends on the type/class of contaminant and which product or item will be affected.
The most hazardous contaminant are;
Allergens
Biological item/product/living organisms
Hormones
Sensitizing materials
Toxic materials/Item
Sensitive product for contamination
Administer booster doses
Injections
Prolong period of time
Product Applied to open wounds
Cytotoxic agents
Consequences to Company
Company image crisis
Financial losses
Loss of Company reputation / Adverse Publicity
License cancellation
Market share down
Product Recall
Show cause notice
Shutdown of premises
Vigorous audit by regulatory authorities
Withdrawal of product
Warning letter
Employee Consequences
Financial losses
Jail / Penalty
Reputation loss
Personal Image crisis
Suspension order
Show cause notice
Termination of services
Minimizing the risk of cross contamination
Minimizing the risk of cross contamination from mix up
Allocation and utility connect expertise that are exclusive to the process
Bar coding, QR coding, and RFID of materials and equipment’s
Distinct dispensing areas
Enormous Electronic confirmation of material
Enormous manual check
Isolated raw material staging area with proper labelling
Using of Color coding
Using of Locked and key Stainless steel cages to store APIs with chain of safekeeping
Using of PAT [Process analytical technology, i.e. NIR]
Minimizing the risk of cross contamination from residue carryover
Cleaning validation
Distinct product contact parts
Equipment design for CIP and SIP
Single use product contact parts
Process Analytical Technology [PAT]/online monitoring
Setting of cleaning limit
Set base limits on statistical analysis, science, and risk assessment
Minimizing the risk of cross contamination from Mechanical Transfer
Airlocks system
Cleaning mobile equipment’s/machine in processing room/area
Encompass at the source
Gowning procedures
HSG [High Shear Granulator], Milling and Drying in same suite
Limiting the transfer of compounds between same suits
Room Airflow
Separate work areas to a single product
Sprinkling showers
Wipe down protocols for mobile equipment’s
Minimizing the risk of cross contamination from Air borne transfer
All the manufactures who are engage to produce Foods, Drugs, Medicine, cosmetics and other healthcare related products want to follow the all basic rule of the GMP/cGMP. This is to be stated here that the compliance of the GMP is very much easy to follow if the facility design perform right way from the start.
To run a smoot operation, this is very important to follow the principles of GMP as well as First Golden Rule of GMP ”Get The Facility Design Right From The Start”.
“If facility didn’t design right way from the first then you may fall in great problem and may be reconsider the whole facility design”
Facility Design
There will be a healthy harmonization between the sequence of facility design where the main target of the facility design is to reduce the mix-up, cross contamination as well as smooth production process. You can’t allow blister packing room near raw dispensing area. The area must be design as such a way that change of non-compliance can be reduce.
A well planned facility design may reduce the overhead of production and least change of product failure. This also prevent back flow and increase productivity to the respective firm. The aim of the best facility design is to –
Lest traffic movement at the production area.
Align the material in specific room/area.
Reduce contamination/mix-up of the products.
Minimize the wrong interpretation.
The target of the good production design is to continue the linear production area so that man and material flow will be unidirectional no backflow the same. The Zigzag and irregular design of the facility tends to misinterpretation of the production design and design failure exhibit predominantly. To apply/introduce/change the existing facility design must be review the SME [Subject Matter Expert].
Environment
This is very important to control the water, lighting, ventilation, temperature, humidity, air etc. so that the respective variable can’t effect the product quality, safety, and efficacy. So the facility must be design must be precisely and risk of non-compliance can be reduce.
A suitable facility must be confirm-
Temperature, Humidity, Pressure, light is appropriate to the standard practice.
The surface of the wall must be free from all types of crack/dam/swelling/dust/rust etc.
Wall must be design in such a way so that it can be clean easily.
All type of drainage must contain 1% slope so that the backflow can be prevent easily.
Equipment
The equipment to be locate, design, install, operate, in such a way so that the intend use can be confirmed to its standard. A standard equipment should be-
Well designed, properly installed, easily operable and easily cleanable.
Easily usable
Properly labeled
Not reactive with the product
Rust free
Calibrated at specific interval
Ten golden rules of GMP
2.0 GMP Golden Rule-2
Validate processes
After design the full facility and equipment of a farm, this the mandatory rule that you must ensure the machine and the facility are operate to its standard but how do you prove this state? Now the term Validation come here first.
Documented evidence is mandatory to prove that the process and equipment doing its own function they supposed to do. To achieve a quality product the consistent function of the machine is essential and this activities can be achieved by effective validation of the process and equipment.
Validation
The validation is the documented evidence which provide the high degree of confidence that specific process will consistently produce a specific product meeting its previously approved specification and related quality parameter.
The validation is the GMP requirements which prove that a specific process, equipment and facility operates right way from the first time to every time without any significant change. The new facility, equipment, process need to validate prior its regular use. Any significant/substantial change in the existing validated system need to validate the system/process/equipment etc.
Validation usually involves:
An equipment/machine generally undergo the several process to complete its validation status. IQ[Installation Qualification] confirms that a specific machine/equipment has been installed correctly to its predefined specifications mentioned its approved IQ protocol.
OQ [Operational Qualification] confirms that the equipment has been successfully installed and operate to its specification mention its approved OQ protocol.
PQ [Performance Qualification], confirms that a specific machine/equipment can produce a product to its predefined specification mention on its approved protocol.
The above all protocol mention the specific process steps, one the work completed successfully a report must be generate to prove the specific activity.
Change control
After completion of the validation programme of the system/equipment/machine/process the maintaining the validation status is important. Once the change is made in any part of the validated facility subject to change control process. A formal change control process must follow to control the whole system. A substantial/ significant change subject to revalidation the system and record must be keep the same.
If a process/part of process/part of the equipment subject to change which may affect the quality of the product need to record keeping through change control process so that the respective firm may overcome regulatory bindings.
Ten golden rules of GMP
3.0 GMP Golden Rule-3
“Write good procedures and follow them”
It can’t be imagine a good company without proper written procedure. An unwanted situation may arise to repeat the specific job from memory. Most of the manufacturer of the firm rely on the experienced operator rather than new one.
This is very logical than an experienced person is always expected to perform the right job but it is not possible to memorize the right job every time may be forget to perform the any specific critical steps resulting failure of the product.
This is the best practice to write down the whole process at actual which perform on the machine/specific stage.
A firm must be document specific not operator specific.
In a foods, drugs, cosmetics industry this is very important that the specific procedure must be clear, concise and logical and must be in place so that anyone can trace and realize it when required and this is the important part of the GMP.
You may consider the SME [Subject Matter Expert]/Third Party Audit Team/Experienced Existing Professional to develop your documentation. When an independent team/party/organization audit your firm they will develop your documented activities and find out your loop hole of the specific process/ procedure/stage and then you will get the huge opportunity to develop it.
List of documents require for standard Firm:
A typical Firm [Foods, Drugs, Medical Device, cosmetic industry] contains the following document but not limited to-
Standard Operating Procedure: Describe the details written procedure/instructions/process to complete the specific task where relevant.
Product/Materials Specification: This the core of the product/Materials which have to confirm/meets to evaluate its quality attribute.
Records Keeping: This state provides history/executed option of the certain products/materials that the products/Materials are following its predefined approved criteria and repeated the criteria each time when produced.
How to write good procedures:
First of all, before writing a good procedure you have to read the all relevant document then start write the main procedure. Use small breakdown of the large paragraph and use Flow Diagram, Chart, Table, Keyword, etc. for precise and easy understanding.
Generally, people don’t have the much time to read the whole procedure from the start to end; want to eye through the whole procedure on the keyword.
A critical/Big process/ procedure can be divided several small things as-
Bold Text
Bullet Points
Charts
Follow Diagram
Heading
Highlighted Text
Image
Instructions
Table
This type of activities reduce the man hour as well as easy understanding the documented evidence. Write down the language in very easy process, where required mother language rather than English use the same for better result. Don’t include extra paragraph for a little information. Write down the whole process in imperative sentence. An ambiguous word mislead the information; so use easy word that is more familiar to everyone.
Use as many simple sentence as possible so that anyone can read it easily. You can follow ALCOA[Attributable, Legible, Contemporaneous, Original and Accurate] and ALCOA+[ Attributable, Legible, Contemporaneous, Original and Accurate with Complete, Consistent, Enduring and Available] method to create a better legible document.
After creating an initial document, printout the same and handover this copy to the relevant personnel and collect the feedback from the personnel and request them to notify which part of the document is confusing and hard to understand the main content of the document.
Mark this section and review the document and apply the correction to the document then you will able to create desirable document for the relevant personnel. This is the method to make a simple standard document but not limited to, you can apply various methods to generate a better documents.
A crated documents need to review it’s periodically to keep it up to date. Most of the company review their document at a Two/Three year’s period. You can review the document yearly or anytime when the relevant topics change based on the available/reliable approved information. Without strong reference/approved information, changing a document create hassle to the existing system.
Follow the written procedures
This is the best practice to have the better written procedure at the place in controlled manner and everyone is following it. A document may be descriptive to the specific process/procedure where alternative/shortcut process/procedure may save the time or you can do it efficiently. Don’t do that.
Do the thing what is written on the document, if require any change, notify the respective authority/your supervisor/Head of Site Quality Person about the issue. Change the document through change control process and until change the document you have to follow the document due to your proposal may not accept if critical change require to apply the proposed change.
You can’t apply your proposed change without approval, due to-
Your process/proposal may not be cost effective in the long run.
Each validated steps/procedure/process has its importance which change may affect the product quality/efficacy/safety.
Ten golden rules of GMP
GMP Golden Rule-4
“Identify who does what”
Every employee must have the clear, precise, specific responsibilities to the respective department. He must know what he supposed to do or what not his responsibility. The specific responsibility will reduce the man hour and better working environment. Every department of the firm must have job description of their employee. A typical job description will contain the specific point such as-
Job Title
Duties and Responsibility
Experience
Total Service length
Service length of the existing firm
Core Responsibility
Additional Responsibility
Administrative Activities
Special Responsibility
The responsibility must be stand alone. No overlapping isn’t acceptable. Doing similar job by multiple employee cause serious misunderstanding and job undone. Better to display the everyone responsibility on the firm notice board at specific department will show that who does what. The cross functional department will easily contact with the responsible personnel if job description available on intranet/sharing folder/common FTP sharing within the firm.
The responsibility may be overlap in the following cases but not limited to-
Calibration Activities
Cleaning Activities
Validation Activities
IPC in multiple section
Production activities
Analytical Activities
Before assigning a specific task for a specific employee, he must be train first and a mock test will be perform before final certification of the employee. An employee must confirm that he is capable for the specific job.
Especially critical activities like Validation of the specific product/process/facility, a series of work to be done precisely without any significant non-compliance, then a person must be assign who is capable to perform the series of task with great responsibility.
Ten golden rules of GMP
GMP Golden Rule-5
“Keep good records”
A good records determine that your system is under control and you are compliance with the GMP which also demonstrate your visibility in terms of quality matters. A good records exhibit that you have followed the all steps and activities describe in the batch production history from dispensing to finished products. This is the part and parcel of the GMP to keep the good records of your production activities.
How to keep Good record?
Make a culture to keep the good record in daily activities. Never try to memorize the activities. Keep your record up to date on the right time at right place.
Don’t perform any type of activities which you are not responsible for or you don’t have proper training to do the same. If you think that the work has been completed without proper documentation then you are in wrong concept. If you are unable to record the activity then it didn’t happen!!
Try to develop less signature option at your document, unnecessary signature creature signature fatigue to the employee.
Record all types of activities carried out during production.
Never try to memorize the activities, record it on time.
Record all type of activities if deviation occur, then inform the Site quality department and take the decision for the same.
Record all type of record in legible ink. Signing any type of record reveal that you are accepting the described activates.
Notify all type of mistakes drawing a single line and write the actual, give the date with sign and mention the reason for the correction.
Documents Record Keeping
Generally you should keep the record of all documented activities. Some important records are-
Analyst Personal Analytical Logbook
Batch Production Records
Cleaning/Equipment Logbook
Cleaning/Equipment Logbook
Environmental Monitoring Records
Material/Product storage condition records
Training Records of Employee
Keep the validation/calibration records life time of the company. Keep batch/production record for expiry date of the product with additional one year. After expiration, keep record for destruction of the document and you can take critical data from the expired documents on validated spreadsheet for further reference. You can keep your document as per your own define period.
Ten golden rules of GMP
GMP Golden Rule-6
“Train and develop staff”
If a firm is properly equipped with the right tools then consider the skilled employee to operate the machine. Document the activities through proper training before starting any type of commercial activates in a validated facility.
Every personnel of the firm must be trained before assigning any type of job. Confirm that the respective personnel have the desired skilled and capability to perform the right job at right time in right place. If you able to do the same then you can develop the GMP culture at your firm.
Training
First of all you have to train the all personnel related to production activities, Laboratory Activities, Quality Assurance activities or whose activities directly affect the quality of the product. Some basic training need to include their training curricula. A training need assessment to be arrange before engaging someone at specific duty.
Some training is common for all employee such as basic GMP training, personal safety and hygiene, Fire Fighting, emergency evacuation plan etc. to be include to the personal training profile.
If any situation occurs, where you have to allow someone to enter the specific area like production then you have to give him some instructions what to do or what not to do, additionally assign a experienced person with him for close monitoring purpose.
Train the employee as relevant as per job description, unnecessary training cause haphazard situation. Identify the group of employee for common training curricula will save your valuable time. Arrange the training as when required.
After completion of the training program certify the employee for specific task and record the same. Initially you may follow up the new employee with the close supervision of a senior experienced skilled person. If everything goes well then give him signing authority to the respective document.
Verified job capability
An employee must prove his job competence during everyday activities producing quality products/documents. After proper training of the respective employee, he must be prove himself that he is very much capable to do the same from the first time to every time in right way.
If he fail to do the specific job then arrange retraining for the same topic then involve the same. If any employee fail to do the same job in several times after retraining then change his job description to the next available job responsibilities.
You can assess the employee through annual appraisal plan, taking record for good/poor activities and discuss the employee with his week point and try to develop it. You can discuss a series of topic with the respective employee-
You must keep the record of all training record of the specific employee including retraining record, evaluation of the specific training at his training record file in a traceable place. A training coordinator to be available to monitor the training activity of the firm.
A person from every department will be responsible to communicate with the training coordinator regarding departmental training activities. Training coordinator will arrange the all type of training of the respective firm.
Ten golden rules of GMP
GMP Golden Rule-7
“Practice good hygiene”
Product contamination will be at higher level if proper hygiene and sanitation program is not maintained. Cleanliness is the key factor in the pharmaceutical industry due to some products like Injections/Infusions are directly administer to the blood stream, if products are contaminated/compromise with pyrogen then any one can face moderate to serious health hazard.
A Standard Operating Procedure [SOP] to be develop regarding hygiene and sanitation. The procedure to be maintained from the first time to every time before starting any type of production activities. A better hygiene practice can develop better GMP culture at your firm. Every employee must confirm to the sanitation and hygiene procedure.
Good to practices in everyday manufacturing-
Maintain personal hygiene everyday by wash your hand, wearing protective gloves, head cover, beard musk, protective musk, hand sanitizer [70%IPA] especially when you are in production area as when required.
Notify your senior/supervisor/authority/Department in-charge/Manager if you are ill/having open wound and probably you are not allowed to manufacturing are till you feel well.
Less/Minimum personnel to be allowed at direct manufacturing/filling area and less product contact to be your first priority.
All type of Eating/Drinking must be prohibited at any type of production/packaging area.
Cleaning and sanitation instructions to be hang on different area of factory premises to increase awareness regarding this issue to the existing employee.
Visitor/Outsider/Auditor Entry to be prohibited to the direct production/manufacturing area.
Notify any type of non-compliance to your Superior/In-charge.
Before starting any batch, remove all type of waste, dust, excess materials except relevant materials.
If possible arrange a personal hygiene and sanitation training program in each month. A schedule may be prepared for different department if it not possible to cover all employee in single time frame. Schedule to be organize in such way that every employee get training at least once in month. If this procedure can develop then you can hope that your firm is conforms to its GMP compliance.
Ten golden rules of GMP
GMP Golden Rule-8
“Maintain facilities and equipment”
Maintenance schedule must be established to facilitate the activities of the daily work. A regular maintenance activities reduce the sudden machine failure during production. Maintenance activities also reduce the product contamination.
A maintenance schedule to be followed effectively and supporting machine parts, oil, coolants, Lubricants, grease, Mobil etc. must be available to continue the activities. Maintenance schedule must be available in place and authorized personnel to be assigned to perform the specific job.
Maintenance Logbook:
A maintenance record must be keep in a specific form and store the same at the custody of maintenance department and must be traceable as when required. Maintenance trend to be done in monthly/yearly basis to identify the machine breakdown frequency and corrective action.
You may use maintenance Logbook for better documentation activities. A maintenance logbook generally contains-
Activities performed
Clean date
Calibration date
Equipment use date
Last maintenance date
Ten golden rules of GMP
GMP Golden Rule-9
“Design quality into the whole product lifecycle”
Personnel engage in Foods, Drugs, Cosmetics, Medical Device Manufacturing company to aware about the safety parameters of the end user[Patient]. Final stage of the products are tested by the Quality Control Personnel to identify/confirms its predetermine specifications only so quality to be ensure all the stage of manufacturing prior marketing in whole product lifecycle.
An inferior quality products tends to degrade in market in a short period of time loss its potency from marginal level fail to confirm its intended use. Patients didn’t receive the desired effect, unable to get early recovery cause unwanted health hazard. The patients start to believe that the product is not fit for him as its fail to satisfy his basic need.
The manufacturing step of the product need to effectively control so that a product can achieve its desired quality parameter through its life cycle.
Checking and Testing of Incoming Materials:
Check all the incoming materials during receiving and sort out the damaged container at specific area to prevent mix-up. Attached “Quarantine Label” to the good one and store it Quarantine area and inform Quality Control Department for Sampling and next activities after completion of Warehousing Activities.
Collect Approval from Quality Control department then use it for manufacturing activities. If the sampled products fail then segregate it and store it Reject Area for further decision[Destroy/Return]
A checklist may be develop to check the basic parameters of the incoming material will prevent the missing/discrepancy of the materials. Purchase order number, material description, quantity, accepted, conditionally accepted, or rejected materials etc. parameters may be add the Checklist for Inspection of Incoming materials.
Manufacturing Process Control
A series of procedure to be perform at the manufacturing of a specific products. Process and procedure must be clearly defined on the Batch Manufacturing Record and the personnel engage in manufacturing activities must be trained properly. A GDP[Good Documentation Practice] to be develop to practice on time record keeping.
Approved master record to be develop and available in a secure place. A batch record must be represent the master record and update document to be issued prior its intended use. All data must be input on specific area of the batch document. All actions must be record including all QMS[Quality Management System] related activities. Specially cleaning activities during/prior batch manufacturing must be record.
Batch Packaging and Labelling Activities
Labeling is the vital part where maximum chance to mix-up of the products. Printed Label to be store securely especially in cut label/single label. Printed label to be store as per batch number/lot number to assure traceability.
Before starting a new batch, all the materials in previous batch must be remove from the packaging line. Follow the Line clearance procedure describe in Batch Manufacturing Record. Record the all activities during product change over and time interval to be define for In Process Control action.
Ten golden rules of GMP
GMP Golden Rule-10
“Perform regular audits”
Internal Audit/Self Inspections to be performed before a face any type of regulatory audit. External regulatory bodies Like UKMHRA [Medicines and Healthcare products Regulatory Agency], FDA [Food and Drug Administration], and TGA [Therapeutic Goods Association] will conduct audit. A self inspection checklist to be prepare and self inspections/Internal Audit to be perform at least once in a year, multiple times in a year may be the best practice.
Self-Audit Checklist
Written Procedures/Specification
Is approved procedure clearly defined the step by step instruction?
Do the procedure follow by the employee?
Is the procedure is up to date?
Is everyone is strictly adhere on the approved written procedure?
Skill
Is everyone is properly educated, trained, experienced in relation to their job?
Is everybody is performing their job right way?
Documentation and Recording
Is document is properly recorded on time?
Is everyone is using legible ink as required to fill the document?
Is all document/critical steps are checked/double checked?
Sanitation and Cleanliness
Is personal good hygiene is in practice?
Is gowning system is properly defined on production/Laboratory?
Is clean equipment’s/machine is stored properly?
Is regular health checkup is in practice?
Maintenance of the Workplace
Is scheduled preventive maintenance perform on time?
Is environment is controlled to minimize product contamination, mix-up, error etc.?
Is equipment logbook is properly maintained?
Quality Control
Is everyone is clear regarding quality control and quality assurance activities?
Is right batch number is declaring from QC department.
IS sampling is properly done & sampling SOP is up to date?
Is all machine calibration up to date?
Quality Assurance Are we concern about quality of our product? If satisfactory result didn’t get then take initiative to implement the same. All audit must be take positively, this the process where we can find our quality related observations and we can update the same.
This is all about the Ten golden rules of GMP which is mandatory to follow for successful operation of an ideal pharmaceuticals. The Ten golden rules of GMP define the ten different areas of a Pharmaceuticals company so this is very crucial to follow Ten golden rules of GMP to develop GMP culture of your firm.
Maintenance of ETP: This SOP [Maintenance of ETP] will make as per SOP for SOP of the respective company/Organization. Font/line spacing/Margin/Page set up/Header/Footer etc. will change as per requirement of SOP for SOP.
1.0 Purpose:
The purpose of this SOP is to define the standard procedure of preventive maintenance of Effluent Treatment Plant [ETP] of XX Pharmaceuticals Ltd.
2.0 Scope:
This Standard Operating Procedure applies to the Effluent Treatment Plant [ETP] of XX Pharmaceuticals Ltd.
3.0 Definitions/Abbreviation:
ACF: Activated Carbon Filter
ETP: Effluent Treatment Plant
MGF: Multi Grade Filter
PAC: Poly Aluminum Chloride
PPE: Personal Protective Equipment
SOP: Standard Operating Procedure
4.0 Responsibilities:
Engineering Department [Validation]:
Preparing the SOP & revise it when required
Engineering Department [Maintenance]:
To provide essential support for maintenance of the system.
To ensure that the operators are accountable to carry out the maintenance.
Operators
To perform the maintenance activities according to the SOP.
Head of Engineering
To confirm that the maintenance of ETP are done correctly.
Head of Quality Assurance
To ensure overall implementation of this SOP.
5.0 Revision Details
Sl. No./Version No./Effective Date/Change History to be add here
6.0 Annexure:
Annexure has been mentioned in bottom of the document with download link
Annexure-I: Maintenance log sheet of ETP
7.0 Procedure:
7.1 Precautions: All maintenance activities must be done safely in accordance with the necessities of the Plant Safety Declaration and the safety notices from place to place the plant. Specific consideration must be paid to the following:
Handle the chemicals by wearing PPE.
Ensure that the pumps are switched off before initiating any kind of maintenance.
7.2 System Description:
The capacity of ETP is 5000 Liter/hour. The effluents from the production department come into the neutralization and equalization tanks via bar screen chambers. In this bar screen chamber the floating material/solid material is being filtered. A dosing of lime is being delivered in the neutralization tank if pH correction is needed.
The effluents are aerated in this tanks with air which is delivered by the blowers. After being neutralized in the neutralization tank the effluents goes into the equalization tank & then the effluent is relocated to the flocculation tank through effluent transfer pumping system.
A dosing of PAC [Poly Aluminum Chloride] is delivered in the flocculation tank to flocculate all the effluents. Poly electrolyte dosing [PED] is delivered in the transferring pipe of effluents from flocculation tank to the lamella.
After lamella the effluent is passed to the aeration tank. In aeration tank the effluents are aerated with air. A dosing of NaOH[Sodium Hydroxide] is provided if it is required.
There is a buffer tank after the aeration tank where 1kg of urea will be delivered after every Two months of operation. There is a line under the buffer tank to transfer the sludge to underground sludge tank & then to sludge pit by sludge transfer pumping system.
Clear water from the Buffer Tank is stored in the clear water tank. There are two pumps to transfer the clear water to final storage tank through MGF [Multi Grade Filter] & ACF [Activated Carbon Filter]. One pump is used at a time.
7.3 Maintenance Procedure:
7.3.1 Maintenance of ETP will be performed according to the following check list:
Type of maintenance: Daily
Maintenance activities:
Clean the screen bar daily.
Clean the surrounding environment of ETP.
Type of maintenance: Weekly
Maintenance activities:
Clean the control panel.
Check the electrical control panel and electrical connection.
Type of maintenance: After 2 months
Maintenance activities:
Clean the dosing tank.
Type of maintenance: After 3 months
Maintenance activities:
Change the oil of blower/compressor.
Type of maintenance: Yearly
Maintenance activities:
Clean all the tanks
Change the gear oil
Clean the clear water tank
7.3.2 Fill up the log sheet (Annexure-I) after performing preventive maintenance of ETP.